Apparatus for pouring ingots



Dec. 1, 1964 E. G. THOMPSON APPARATUS FOR POURING INGOTS 2 Sheets-Sheet 1 Filed Sept. 7, 1960 INVENTOR. ELMER G. THOMPSON. WZMJQS ATTORNEYS 1964 E. G. THOMPSON 3,158,911

APPARATUS FOR POURING INGOTS Filed Sept. 7, 1960 2 Sheets-Sheet 2 FIG. 3 G3 1 EiL 5 6 4 k 5| INVENTOR. 1 ELMER G- THOMPSON ATTORNEYS.

United States Patent This invention relates to the pouring of steel and other metals into ingot molds. More particularly, this invention relates to a method and apparatus for pouring steel and the like.

When molten steel from a ladle falls a distance of ten to twenty feet and hits the bottom of a mold, terrific erosion and splashing takes place, necessitating frequent replacement of the stool or ingot mold itself. The erosion frequently, due to under-cutting in the case of certain types of big end-up molds, may prevent or seriously hinder the removal of the ingot from the mold. An object of this invention is to provide a method and device for pouring molten steel and the like which minimizes or eliminates the erosion of the bottom portion of big end-up ingot molds or the stool in the case of big enddown molds.

In the usual pouring of steel and the like into ingot molds, there is a splashing of the steel against the walls of the cold ingot molds when the molten metal the stool or mold bottom of big end-up molds and splashes therefrom. Also, as the level of the steel rises in the ingot mold, there is a splashing of droplets on the mold walls. Small droplets or beads of metal quickly chill on the walls of the molds, and these myriads of droplets are seldom remelted as the level of the molten metal rises in the mold, and therefore become occluded in the surfaces of the ingot itself and do not become a part of the ingot except as an impurity, imperfection, 01' as a source of weakness. in the further processing of steel and the like, the ingot is removed from a mold and placed in a soaking pit before rolling in the blooming mill, which reduces the size of the ingot to the desired end product, whether it is blooms, slabs, billets, bars, plates, etc. During the rolling process, the small uumelted droplets imbedded in the surfaces of the ingot become elongated and widen becor ing cracks and flaws which, if not removed some place i the rolling practice, would appear, no m ter how thin the steel was rolled. in the case of rails, axles, bridges, aircraft parts, and other structural or 'ubers, these cracks are direct causes of failure and d er to life and limb. Great expense in labor and time is spent in removing these faults by various methods such as grinding, fiame scarfiug, chipping, and the like, all of which are costly and diflicult. A further object of this invention is to provide a method and device for pouring steel and the like into ingot moldswl'ich prevents splashing of the metal on the mold walls during pouring.

In the practice of my invention, an upright tube is mounted inside the ingot mold. The tube extends from adjacent the discharge spout or outlet of the ladle to the bottom of the big end-up ingot mold or to the stool of the big end-down ingot mold. This tube is formed of inorganic fibrous material such as asbestos, glass, ceramic or other heat-resistant, substantially non-heat conductive inorganic materials which are of m gravity than and are substantially insoluble in the metal poured. The tube is made sufli iently strong to contain the metal as the pouring starts, and, as the metal is poured, the heat and weight of the metal causes the lower end of the tube to disintegrate and decompose and rapidly break up into particles which float on the molten metal surface. lien pouring of the ingot is completed, these particles float on the top surface thereof and they can be readily removed with other impurities whic. Float ice on the metal during processing of the ingot. The particles are ordinarily of a feathery nature when the tube is formed of asbestos. The tube can be formed of fibers woven or matted and formed or shaped into a tube. The inorganic fibers in the form of a mat of which the ube is formed, can be impregnated with a suitable inorganic resin or adhesive such as an alkali metal silicate or the like to strengthen the tube and unify the structure thereof.

The above and other objects and features of the invention will be apparent to those skilled in the art to which this invention pertains from the following detailed description and the drawing, in which:

FIG. 1 is a view partly in side elevation and partly in lengthwise section, showing a series of big end-down ingot molds placed on stools which are mounted on wheeled carriages, the mol s being shown in association with a pouring ladle, pouring tubes being mounted therein;

FIG. 2 is a plan view of the ingot molds shown in FIG. 1;

FIG. 3 is a plan View of a big end-up ingot mold carryin a pouring tube;

FIG. 4 is a view in section taken on the line 4-4 in- FIG. 3, showing the mold in association with a pouring ladle;

FIG. 5 is a view in side elevation of the pouring tube, shown in FIGS. 3 and 4;

FlG. 6 is a view in section taken on the line 6--6 in FIG. 5;

FIG. 7 is a perspective view of a plug which forms a part of the ingot mold shown in FlGS. 3 and 4;

8 is an enlarged fragmentary view in section taken on the line l-4 in FIG. 3;

PEG. 9 is a fragmentary view in side elevation showing the lower end of the pouring tube illustrated in FIGS. 1 and 2; and,

FIG. 10 is a fragmentary view in' section taken on the line l@lil in FIG. 9.

in the following detailed description and the drawings, like reference characters indicate like parts.

In FIGS. 1 and 2 is shown a train of ingot molds 12. Each mold rests on a heavy horizontal slab of iron or steel forming a stool 13. Each mold 12 is removably mounted on the upper surface of the stool 13 and is an upright, hollow, rectangular body mold section, the walls 16 of which slope inwardly and upwardly to form a customary big-end-down mold. Each stool 13 can be mounted on a wheeled carriage 17 supported by wheels 1%. The carriages are shown linked together or connected by couplings 19. A ladle 29 is arranged to travel above the open ends of the molds in a conventional manner. The ladle 2G is provided with an outlet opening 21 formed in the bottom thereof through which a stream of molten metal 22 can flow under control of a valve 23. The flow of metal is-controlled for filling the ingot molds in succession.

Inside each ingot mold is mounted a filler tube 24. Each filler tube is formed of inorganic fibrous material such as asbestos, ceramic, glass fibers, or other heatresistant, substantially non-heat conductive fabric or matting which can be impregnated with an inorganic filler and binder of sodium or calcium silicate or other alkali metal silicate or other appropriate inor anic binder, or chemically by the use of phosphoric acid and the like. The tube in a preferred form is constructed of asbestos fibers of the type known as crocidolite which is particularly suitable because of its low water of crystallization. The fibrous mat rial and the binder should be substantially free of materials which can injuriously affect the metal being poured. In particular, where steel and the like is to be poured, the tubes should be substantially free of boron and other materifls which, in small amounts, give steels undesirable characteristics. Preferably the filler tube is formed of h'elically wound laminations bonded together by such binder and filler material. The bottom of the tube can be closed by a round plate portion 26 which can be made of similar inorganic fibrous material and can be attached to the bottom" end of the tube'by a similar binder. I V

The lower portion of the tube can be provided with a plurality of openings 27 the square inch or cross-sectional areaof'which should be approximately equal to the square inch or cross-sectional area of the outlet opening in thebottom of the ladle. These allow the molten metal to flow out of'the tube and will prevent the tube from filling too rapidly and overflowing the top. They will also hasten the disintegration and decomposition of the lower portion of the tube; The lower portion of the tubealso can be wound spirally with a pressure sensitive continuous parallel laid filament glass tape or asbestos cord 27a for a distance of approximately one foot. This will materially increase the tensile or hoop strength of that portion of the tube and enable it to withstand the initial shock loadagainst the inside Wall of the tube when the operator opens the valve 23. A thin layer or sheet 27b of the iorganic fibrous material can underlie the tape or cord 27a covering the openings 27.

The length of the tube is determined by the height of the ingot mold and the inside diameter is determined by the outlet hole in the ladle. Ordinarily, for large molds of say, five tons capacity an inside diameter of four (4) inches to six (6) inches is satisfactory with a wall thickness of inches to 7 inches. The layer or sheet 27b can be approximately A inch thick.

A well 28 having its inside diameter approximately equal to the outside diameter of the tube can be formed at the center of'each stool 13 and this well, approximately one (1) inch deep, receives the lower end of one of the tubes. spider arrangement having a central tubular ring portion 31 inside which the tube is received and arms 32 which extend to and overlie the walls of the ingot molds, preferably at the corners as shown. Inverted U-shaped sockets 33 at the ends of the arms 32 overlie the walls.

As the molten metal is poured, the metal hits the plate portion 26 of the tube, which reduces or eliminates erosion of the central portion of the stool. As the metal is poured into the tube, the metal escapes and flows through the openings 27. Almost immediately and within seconds, the lower portion of the tube starts to disintegrate and decompose as the molten metal is rapidly poured therein. However, the walls of the tube stop any spattering drops and prevent droplet formation on the wall of the ingot mold. The tube does not disintegrate as rapidly as the metal rising in the mold because the tube is substantially a non-conductor of heat. Hence the lower portion or end is actually slightly below the level of the molten metal in the ingot mold, thereby preventingthe further splashing against the ingot mold walls, as the level of steel rises and until the mold is filled. However, as'the ingot mold rapidly fills, the tube disintegrates and decomposes within the molten metal, and the feathery particles of the tube float to the top where the particles can be readily removed, because the inorganic fibrous material, such as asbestos or the like, is much lighter than the molten metal and floats thereon. The ingot can then be permitted to cool, whereupon the ingot mold is removed therefrom and the top portion may be cropped oft in a later operation as is present practice to remove any impurities of the tube or slag which floats thereon.

*In FIGS. 3 and 6 inclusive, is shown an embodiment of the invention in which a pouring tube 4-1 is shown mounted in a big end-up ingot mold 42. The mold 42 is provided with an opening 43 in the bottom thereof 7 {which is of frusto-conicshape and in which a knock-out plug 44 is mounted. Details of construction of the knock-out plug are shown in FIG. 7. The plug 44 has a frusto-conic main portion or body as and a cylindrical upper or head portion 47 integral therewith. The diameter of the head portion is substantially the same as the inner diameter of the tube il, so that the lower end of the tube can embrace the head portion, as shown in PEG. 4, with the lower end of the tube resting on a shoulder d8 of the plug 44. The upper end of the tube 41 is supported and steadied by a spider having a central ring 51 or section of steel tubing, which embraces the upper portion of the tube, and arms 52 which terminate in inverted U-shaped support portions or sockets 53. The support portions 53 overlie preferably the corner Walls of the ingot mold to support the spider. clearly in FIG. 8, set screws 54- in the central ring 51 can engage the tube to hold the tube in position.

The tube 41 can be made of the same type of material as the tube already described. The lower portion The upper end of the tube is supported by a of the tube 41 is provided with a plurality of openings 55 similar to the tube already discussed. If desired, the openings can be covered with a winding of filament glass tape 55a or asbestos roving as outlined above Molten metal such as steel, is poured into the tube ll. iroma ladle 56. Flow of metal is controlled by a valve 57. The metal =falls against thehead portion of the plug 44 so that the erosion takes place on the head of the plug. As the metal is poured, the tube 41 stops any droplets which tend to spatter during pouring, and prevents the droplets and splashings reaching the side walls of the ingot mold.

Then, as the level of metal rises, the lower end of the tube disintegrates and decomposes into feathery particles which float to the top of the molten ingot. The tube does not disintegrate as rapidly as the metal rising in the mold because the tube is a substantially non-conductor of heat. Hence the lower portion or end is actually slightly below the level of the molten metal in the ingot mold, thereby preventing the further splashing against the ingot mold walls as the level of the steel rises andnntil the mold is filled. When the ingot has been cooled, the ingot mold can be raised by means of handles 58, and the plug 44 can be tapped to release the ingot from-the mold. Inasmuch as the chief erosion occurs only on the head of the plug 44, the plug can be discarded after one or more usages and little or no erosion of the ingot mold occurs.

' The method and devices illustrated in the drawings and described above are subject to structural modification without departing from the spirit and scope of the appended claims.

Having described my invention, what I claim as new anddesire to secure by Letters Patent, is:

1, The combination of an ingot mold with a tube of inorganic fibrous material substantially insoluble in the metal poured and of a-substantially difierent specific gravity from the metal poured, there being a well in the stool supporting the mold, the lower end ofthe tube being received in the well and being held in position by walls of the well, the tube being upright and extending from the well to adjacent a pouring opening of a ladle of molten metal, a round plate of such material in said well and spanning the lower end of the tube, the tube stopping splashing droplets of metal as the metal is poured, the tube decomposing and disintegrating as the level of metal rises thereabout, the material of the tube gravitationally separating from the poured metal.

2. The combination of an ingot mold having an opening in the bottom thereof, a plug closing the opening, the

plug having a head extending upwardly into the interior As shown most plug to adjacent a pouring opening of a ladle of molten metal, the molten metal falling against the head of the plug, the tube stopping splashing droplets of metal as the metal is poured, the tube decomposing and disintegrating as the level of metal rises thereabout, the material of the tube gravitationally separating from the poured metal.

3. A combination in accordance with claim 2 in which the plug is provided With an upwardly facing annular shoulder snrrouding the head, and in which the lower end of the tube rests on the shoulder.

4. The combination of an ingot mold with a tube of inorganic fibrous material substantially insoluble in the metal poured and of a substantially different specific gravity from the metal poured, the tube being upright and extending from the bottom of the mold to adjacent a pouring opening of a ladle of molten metal, the lower portion of the tube being provided with openings to permit gradual escape of the metal, and a spiral winding of substantially parallel inorganic fibers overlying the openings to reinforce the lower portion of the tube, the openings penrnitting decomposing and disintegration of the tube as the metal is poured, the material of the tube gravitationally separating from the poured metal.

5. The combination of an ingot mold with a tube of inorganic fibrous material substantially insoluble in the metal poured and of a substantially different specific gravity from the metal poured, there being a Well in the stool supporting the mold, the lower end of the tube being received in the well and being held in position by walls of the well, the tube being upright and extending from the well to adjacent a pouring opening of a ladle of molten metal, a plate of such material in said Well and spanning the lower end of the tube, the tube stopping splashing droplets of metal as the metal is poured, the tube decomposing and disintegrating as the level of metal rises thereabout, the material of the tube gravitationally separating from the poured metal.

6. The combination of an ingot mold with a tube of inorganic fibrous material substantially insoluble in the metal poured and of a susbtantiaily different specific gravity from the metal poured, means on a bottom portion of the mold spaced from Walls of the mold and engaging a lower end of the tube to hold the lower end of the tube in spaced relation with walls of the mold, and means spaced above the bottom of the mold for holding the tube in an upright position with an upper end of the tube adjacent a pouring opening of a ladle of molten metal, the tube stopping splashing droplets of metal as the metal is poured, the tube decomposing and disintegrating as the level of metal rises thereabout, the material of the tube gravitationally separating from the poured metal.

References Cited in the file of this patent UNITED STATES PATENTS 1,540,269 McNally June 2, 1925 2,763,043 Grant Sept. 18, 1956 2,976,587 Daussau Mar. 28, 1961 FOREIGN PATENTS 1,023,443 France Dec. 30, 1952 

1. THE COMBINATION OF AN INGOT MOLD WITH A TUBE OF INORGANIC FIBROUS MATERIAL SUBSTANTIALLY INSOLUBLE IN THE METAL POURED AND OF A SUBSTANTIALLY DIFFERENT SPECIFIC GRAVITY FROM THE METAL POURED, THERE BEING A WELL IN THE STOOL SUPPORTING THE MOLD, THE LOWER END OF THE TUBE BEING RECEIVED IN THE WELL AND BEING HELD IN POSITION BY WALLS OF THE WELL, THE TUBE BEING UPRIGHT AND EXTENDING FROM THE WELL TO ADJACENT A POURING OPENING OF A LADLE OF MOLTEN METAL, A ROUND PLATE OF SUCH MATERIAL IN SAID WELL AND SPANNING THE LOWER END OF THE TUBE, THE TUBE STOPPING SPLASHING DROPLETS AND DISINTERGRATING AS THE LEVEL OF METAL 